Guideline 000.200.

1067
Date 30Mar2015
Page 1 of 8

3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

PURPOSE

The purpose of this Guideline is to provide information on how to approach the design
for maintenance of equipment and other components which require maintenance on a 3rd
Gen Modular ExecutionSM project. This document could apply to any project whether
stick built of modular but must be applied on a 3rd Gen Modular ExecutedSM project.

The Guideline will be used by engineering disciplines and Owner’s Operations and
Maintenance personnel developing maintenance strategies.

SCOPE

This Guideline comprises of the following sections:

• Application
• Interfacing Disciplines
• Definitions
• Material Handling
− Material Handling Strategy by Project Phase
− Material Handling Matrix - Equipment Information
− Material Handling Matrix - Material Handling Strategy
− Material Handling Matrix - Example
− Engineering Discipline Inputs
− Material Handling Strategy Review
• References
• Attachments

APPLICATION

This document is to be used by all engineering disciplines and the Engineering Manager
and/or Module Coordinator for the development of the Material Handling Strategy and
associated Material Handling Matrix.

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

INTERFACING DISCIPLINES

The following disciplines have been identified as having interface responsibilities in this
activity:

• Control Systems
• Electrical
• HVAC
• Mechanical
• Structural
• Piping
• HSE
• Engineering Manager / Module Coordinator
• Owner’s Maintenance representative

DEFINITIONS

Material Handling – this term refers to the design required for handling of equipment
and other components within a process facility which require some form of removal for
maintenance.

MATERIAL HANDLING

Equipment is located in a base Module at grade with a pipeway level included in the
Module and another Module above if additional pipeway space is required or if there is a
need for equipment on top.

If equipment in this base Module is required to be removed, lifting devices such as

monorails, jib cranes, or bridge cranes are installed between the equipment and the first
level of the pipeway. Equipment can be removed at the ends of the Modules where drop
zones are identified. Every effort is made to not allow equipment to be lifted over top of
other equipment as it exits the Module. If Monorails are used for lifting, “Switches” can
be used to assist with centralizing a common monorail. Refer to guideline 000.200.1063
3rd Gen Modular ExecutionSM Design Guideline

Since the 3rd Gen Modular ExecutionSM design produces a more compact layout it is
extremely important that consideration is given to be able to operate and maintain all
components. The most effective tool to address this is completing a “Material Handling
Matrix”. This matrix provides assurance that all components greater than 30 kg in weight
have the ability to be removed or effectively replaced for maintenance or operating
conditions.

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

Completing this matrix will require collaboration and input from all disciplines. The
Engineering Manager or Module Coordinator should champion the completion of this
matrix.

Material Handling Strategy by Project Phase

DBM or FEL 2 Phase:

• The material handling strategy and matrix practice should be initiated during this
phase so that it can be effectively implemented during the next phase.

EDS Phase

• Identify larger equipment that requires handling strategy

• Identify weights and sizes of this larger equipment
• Identify material handling methods for movement of that equipment

Detailed Design Phase

• Identify all equipment greater than 30kg that requires handling strategy
• Identify any special installation, assembly requirements for modularized equipment
• Identify maintenance and disassembly (e.g., exchanger bundle pull-out) dimensions
of the equipment
• Identify lifting and transportation strategy for each piece of equipment

Material Handling Matrix - Equipment Information

The Material Handling Matrix provides an itemized inventory for the handling of all
facility equipment / components above 30kg for operations and maintenance purposes.
All equipment in the facility above 30kg should be included in the Material Handling
Matrix.

The matrix should include a description and tag number for the equipment and the total
weight of that equipment.

The weight of the heaviest component of that equipment to be operated, maintained or

replaced should be included in the matrix.

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

The expected frequency of maintenance should be identified using the following criteria:

1. Frequent
2. Every 1-2 years
3. Every 2-5 years
4. Every 5-7 years
5. Once or twice during life of facility

The impact on production due to removal of a piece of equipment should be included in

the matrix. “No” would indicate that the temporary loss of service will not impact
production or that a spare is available and can replace the out-of-service equipment.

Maintenance dimensions should be included in the matrix for each item.

The combined weight of the equipment and the transportation equipment should be
included as the Access Route Loading.

Equipment information should be updated on an ongoing basis throughout the project as

vendor information is clarified and weights, lifting details, and equipment/skid package
dimensions, including any overhung components (e.g. junction boxes of skid mounted
large motors) and dimensions are confirmed.

Material Handling Matrix - Material Handling Strategy

Considering the frequency of maintenance and importance of removal as described

above, a lifting strategy should be provided for each piece of equipment included in the
matrix.

The lifting strategy will identify what type of permanent or portable Operating and
Maintenance Material Handling equipment will be utilized to operate, maintain or replace
that piece of equipment.

The following Operating and Maintenance Material Handling equipment can be

considered:

• Monorail / Trolley Hoists for weights below 2.5 tonnes

• Hydraulic Tube Bundle Puller for Shell & Tube Heat Exchangers
• Fixed Jib with Hoist for handling material with agility & flexibility
• Bridge Cranes to suit heavy equipment exceeding 2.5 tonnes with periodic
maintenance
• Cranes for outdoor equipment with crane access

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

A transportation strategy should be provided for each piece of equipment included in the
matrix.

The transportation strategy will identify an appropriate means for safely and efficiently
relocating equipment / components to a planned lift / laydown area for transport, in the
case of off-site maintenance or replacement.

Note: All equipment requires a transportation strategy in case of any requirement

to remove the equipment from the building.

Where access permits, the following mobile transportation equipment should be

considered:

• Manual Cart
• Forklift
• Truck

It may also be useful to include in the matrix where a laydown area has been designated
for that particular piece of equipment.

Material Handling Matrix - Example

An example of a Material Handling Matrix is included below:

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

Engineering Discipline Inputs

The following information provides some example of what each discipline might
consider to be included in the Material Handling Matrix.

Mechanical

• Shell & tube heat exchanger bundle

• Motor
• Weight of internals or items requiring maintenance (e.g. filters trays etc.)
• Pump, driver rotor
• Compressor, driver rotor
• Tank heater and mixer
• Gear box

Electrical

• Distribution Panel
• Battery (breaker, charge, bank)
• Switchgear
• VFD
• Transformer
• Cable Bus
• MCC
• EHT Equipment
• UPS System

HVAC

• Unit heater
• Electric heater unit
• Exhaust fan
• Air handling unit
• Pressure relief damper
• Air cooled condensing unit

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
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3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

Instrumentation

• Cabinet
• Panel
• Orifice Plate
• Transmitter
• Control Valve
• Gauge
• Relief Valve

Piping

• Blind flanges
• Spacers

Material Handling Strategy Review

It is suggested that the Material Handling Matrix is put on squad check prior to Model
Review #1. During this squad check, the following items should be reviewed:

• Each discipline to check the completeness of the document

• Piping to check the suitability and availability of the lift strategy against the model

• Client Operations & Maintenance personnel to check the expected maintenance

frequency

It is recommended that Client Operations & Maintenance Representatives are engaged

early to obtain alignment on operation and maintenance concepts

Model Development review meetings can be held for each area prior to Model Review
#1, which can be used as a forum to gain acceptance from the Client personnel on
material handling strategies.

It is suggest that the Material Handling Matrix is issued after Model Review #1 to capture
any changes or comments regarding the material handling strategy. Subsequently it is
suggested that the Material Handling Matrix is issued before and after Model Reviews #2
& 3.

Final acceptance of the Material Handling Strategy for all equipment can be reviewed in
Model Review #3.

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
Page 8 of 8

3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

REFERENCES

000.200.1063: 3rd Gen Modular ExecutionSM Design Guideline

000.200.1065: 3rd Gen Modular ExecutionSM Model Review

ATTACHMENTS

Attachment 01 Material Handling Matrix template

Available as Excel File in KOL (with this guideline)

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering

 Guideline 000.200.1067
Date 30Mar2015
Attachment 1 - Page 1 of 1

3RD GEN MODULAR EXECUTIONSM MATERIAL HANDLING STRATEGY

MATERIAL HANDLING MATRIX TEMPLATE

Copyright © 2015, Fluor Corporation. All Rights Reserved. Engineering